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Old 02-11-2022, 10:52 PM   #11
cartdoc1969
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Default Re: No voltage at brake plug, rxv cart won’t move

I would look over the troubleshooting guide USGI posted. First thing I would check is for the 5VDC from the controller.
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Old 02-17-2022, 06:09 PM   #12
HvacCommander
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Default Re: No voltage at brake plug, rxv cart won’t move

Ideas on where I should start checking in this manual? I don’t have a ton of time to devote to learning this thing up one side and down the other. Maybe just a general order of things to check. Where would I check 5vdc from controller first? And at what position should the switches be in when I check.
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Old 02-17-2022, 07:07 PM   #13
cartdoc1969
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Default Re: No voltage at brake plug, rxv cart won’t move

If you have a set of piercing probes for your meter you can check at the main controller plug. Pins 3 and 4 are the 5VDC for the sensors. The next easiest place would be the bearing encoder connector at the motor, it's the 4 pin connector on the motor. Use the orange and black wires, you can check with it unplugged. That plug only has 5VDC so there's no risk of shorting it to the 48V side. Key switch can be in any position, same with run/tow. As long as the controller has 48V feeding it the 5V side should be there.

Does your cart have the original parking brake with the lever attached ?
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Old 02-18-2022, 01:47 PM   #14
HvacCommander
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Default Re: No voltage at brake plug, rxv cart won’t move

I’ve never seen a parking brake lever, I bought it used so could’ve been removed?
I need to get a set of piercing probes asap, been meaning to anyway for work.
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Old 02-18-2022, 04:50 PM   #15
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Default Re: No voltage at brake plug, rxv cart won’t move

I have zero volts dc at motor plug on orange and black.
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Old 02-18-2022, 10:04 PM   #16
cartdoc1969
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Default Re: No voltage at brake plug, rxv cart won’t move

A few possibilities I can think of.

First and worst case is the controller has failed. There's two ways to know that for sure. Have someone with the handheld reader to check the controller for error codes and test it. Other way is to test the harness and all components to rule everything else out.

Second possibility and more likely. A failed sonic weld in the wiring harness. The piercing probes would help find that out. The 5 volts for the sensors leaves the controller on the orange wire on pin 3. That wire splits and four wires come off it at the sonic weld. Those connection points can fail, especially on the older harnesses. Best way to access it is to remove the front batteries and open up the loom protecting the wires. You'll see the red wire one, the orange one and a black one. Remove the tape and inspect them. If they are corroded or look bad just cut them out, solder the wires together and use heat shrink to cover the new connection.

Last possibility is one of the sensors is bad and is pulling the 5 volts down. Best way to test that is to disconnect the brake and accelerator pedal sensors, the motor encoder, the SOC meter if it has one and the resistor control module. Check the voltage again on pins 3 & 4 on the controller. If you now have 5VDC then it's one of the items disconnected that's bad and puling the voltage down.
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Old 03-03-2022, 06:33 PM   #17
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Default Re: No voltage at brake plug, rxv cart won’t move

I unplugged all the connectors I could and I still don’t have 5vdc on orange and black at controller plug. Does this mean it’s the controller? If so, what am I looking at price wise for a danaher controller or a conversion?
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Old 03-03-2022, 07:37 PM   #18
cartdoc1969
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Default Re: No voltage at brake plug, rxv cart won’t move

It does sound like the controller failed. The Danaher hasn't been available for a few years and I would avoid the repair services. I just replaced one that was shorted out with a 600A Navitas. I paid $ 835 for the kit with the on the fly module. Like everything else right now the prices are higher. It is an easy change, took maybe 1 hour.
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Old 03-04-2022, 05:57 AM   #19
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Default Re: No voltage at brake plug, rxv cart won’t move

The 600amp Navitas is still available for 830$, just checked the seller of mine... if you won't
need the included OTF, it will save 120$.
And it's the new style kit, direct fit w/o any adapter needed!
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Old 03-22-2022, 07:42 PM   #20
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Default Re: No voltage at brake plug, rxv cart won’t move

Looks like I’m taking back to where I bought it so they can hook it to their handheld. I fear it’s the controller myself, not planning to spend almost 1000$ to fix it either. May not have a choice. Hopefully that’s just worst case and I’m not checking something right or missed a step🤞🏻.
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